On my second attempt, I know that I was more worried about limiting operator error as the root cause of the problem to be thinking outside of the box. Knowing what I know now, perhaps a smaller bit would work, though it would have to be only a whisker’s difference. As the sets of holes must be absolutely parallel to the fence, this might be just enough to skew them off. Unfortunately, or, fortunately, I won’t be doing any further testing on this. Getting to be a bit too rich for my blood! Haha! I have convinced myself that I will be satisfied at this point. That is, unless Microjig agrees that their plastic jig is not designed to stand up to the 10,000 degree drill bit that is the result of following their directions and using a phenolic insert. I will not hold my breath on that one. Thanks for the input; maybe someone else will have a go at it and let us know.
-- Erik, bauernhof holzwerke, Fayston, Vt.
